Topless Mustang is On Top

As the world honors 50
years of Ford Mustang, what better way to celebrate one of the most
iconic car brands than putting one back on top of one of the most iconic
buildings? When Ford and the Empire State Building decided to display a
new 2015 Mustang convertible on the 86th floor observation deck, Ford
turned to a longtime supplier for the unique expertise required to make
this happen. In a world where tiny startups
are regularly swallowed up by established behemoths, Ford Motor Company
and Romulus, Mich.-based DST Industries have been collaborators for
nearly six decades. In 1965 – the only other time in the Empire State
Building’s 83-year history a car was displayed on its open-air deck – a
DST crew was on hand to show off that Mustang convertible.

“This week, the band is getting back together as Ford and
DST bring the all-new Mustang to the Empire State Building to honor 50
years on sale,” said Dave Pericak, Mustang chief engineer. “We’ve taken
the new Mustang to new heights of technology and refinement, so we
decided to take it to new heights literally for this celebration.”

The all-new Mustang may be more advanced than ever before, but
sometimes physical limitations demand old-school techniques to get a job
done.

“When our engineers sat down with the DST team to start
plotting this out in mid-February, everyone quickly realized that some
old-school craftsmanship would be needed to successfully place this car
more than 1,000 feet above the crowded streets of Manhattan,” said
George Samulski, manager, Ford North America design fabrication.
“The deck is too high to reach with a portable crane from the street,
and the spire that towers more than 400 feet above that narrow deck
makes helicopter delivery impossible.”

The only other car display on the Empire State Building observation
deck happened in October 1965, when a crew from DST, including retired
technician Claude Cochran, sectioned a Mustang convertible so that it
could be fit into the elevators of the building.
Following a site inspection in New York to meticulously measure all of
the elevators and doors, the engineering team in Dearborn sat down with a
scale model of the new Mustang and started drawing lines on it with a
marker to represent where it should be cut. The Empire State Building is
a historic landmark, with original art deco wood and brass trim in the
elevators, so it was crucial to ensure everything have plenty of
clearance.

“The only real problem we had in 1965 was the steering
wheel,” said Cochran. “When we tried to roll the middle section of the
car with the windshield removed into the elevator, the top of the wheel
stuck out a bit too far through the door, so we had to tip the cart a
bit to get it in.”

In preparing for the 2014 event, the team at DST worked with two
early prototype Mustang convertible body shells. The car that would
ultimately make the trip to New York was completely stripped down and
the surface cleaned up to make sure everything looked perfect before it
was sectioned and painted.

The second body was used as a donor by DST metal fabricators to
determine where to make the cuts and to fit a custom-built tubular steel
subframe that would hold all the sections together. The fabricators
built custom rolling carts and wooden crates for each section.

Getting from the loading dock to the observation deck requires riding
a freight elevator and two separate passenger elevators. A wood mockup
of the smallest elevator was built in the DST shop in Romulus to verify
everything would fit. Each of the loaded carts was then weighed to
ensure everything stayed within the weight limits of the elevator and
the observation deck.

“The observation deck is open to the public from 8 a.m.
to 2 a.m., leaving our crew of six with only a six-hour window to get
everything out onto the deck and get the car assembled,” said Pericak.
“Before we shipped the crates to New York, the crew spent several days
practicing the entire assembly process – timing everything down to the
minute – much like a NASCAR or Formula One pit crew.”

With several weeks of fabricating and practice behind them, and the
crates on a truck and headed to New York, the DST crew is resting up
ahead of some long nights this week assembling and disassembling the
Mustang.

The Triple Yellow 2015 Mustang convertible will be on display for
visitors to the Empire State Building observation deck April 16-17. When
the deck closes to the public at 2 a.m. April 18, the crew will descend
on the display car to reverse the entire process and remove it before
visitors return at 8 a.m.